PROCESSING THERMALLY PRETREATED AND UNTREATED BATTERIES AND THEIR PRODUCTION REJECTS

Abstract

Embodiments of the present invention relate to a system for processing battery waste. The system comprises a decomposing device for mechanically decomposing the battery waste to a, in particular strip-shaped or flake-shaped, lightweight portion and a heavyweight portion. The decomposing device comprises an outlet for commonly discharging the lightweight portion and the heavyweight portion. The system further comprises a separating unit for separating the lightweight portion from the heavyweight portion, wherein the separating unit is coupled with the decomposing device for receiving the lightweight portion and the heavyweight portion. The system further comprises a fiber compactor unit, wherein the fiber compactor unit is coupled with the separating unit for receiving the lightweight portion. The fiber compactor unit is configured for compacting the lightweight portion under a separation of a further active material.

Claims

1. System for processing battery waste, the system comprising a decomposing device for mechanically decomposing the battery waste to a, in particular strip-shaped or flake-shaped, lightweight portion and a heavyweight portion, wherein the decomposing device comprises an outlet for commonly discharging the lightweight portion and the heavyweight portion, a separating unit for separating the lightweight portion from the heavyweight portion, wherein the separating unit is coupled with the decomposing device for receiving the lightweight portion and the heavyweight portion, and a fiber compactor unit, wherein the fiber compactor unit is coupled with the separating unit for receiving the lightweight portion, wherein the fiber compactor unit is configured for compacting the lightweight portion under a separation of a further active material.

2. System according to claim 1, wherein the mechanical decomposing device forms an impact reactor, in particular with a shredder rotor.

3. System according to claim 2, wherein the decomposing device comprises an upper inlet for filling in the battery waste, wherein the battery waste is conveyable to the inlet, in particular by an ascending conveyor.

4. System according to claim 1, wherein the outlet is closable, in particular by a controllable flap, such that the outlet is selectively opened for conveying the decomposed battery waste out of the decomposing device.

5. System according to claim 4, wherein the flap is configured for sequentially opening and for discharging the lightweight portion and the heavyweight portion through the outlet for a predetermined discharging time, wherein the discharging time is 0.25 min to 5 min, in particular 2 min.

6. System according to claim 1, wherein the separating unit is arranged downstream of the outlet.

7. System according to claim 1, wherein the separating unit comprises a sieve for separating the lightweight portion from the heavyweight portion.

8. System according to claim 1, wherein the separating unit is a flow classification.

9. System according to claim 8, wherein the separating unit comprises a blower for generating an air flow, wherein the blower is controllable such that, by the air flow, the lightweight portion is separatable from the heavyweight portion, and the lightweight portion is conveyable to the fiber compactor unit.

10. System according to claim 9, wherein the separating unit comprises a downpipe, in which the lightweight portion and the heavyweight portion are conveyable along a conveying direction in a loose manner, in particular vertically falling, wherein the blower guides the air flow substantially perpendicular to the conveying direction, such that the lightweight portion is separatable from the heavyweight portion by the air flow.

11. System according to claim 1, wherein the fiber compactor unit comprises a perforated plate, on which the lightweight portion is placeable, wherein an air flow from the separating unit transports the lightweight portion in the fiber compactor unit, wherein the air flow is directed such that the air flow passes the perforated plate and pushes the lightweight portion against the perforated plate and blows a further active material portion through the perforated plate, wherein the fiber compactor unit comprises a stripping unit for stripping off the lightweight portion from the perforated plate.

12. System according to claim 1, wherein the fiber compactor unit comprises a cyclone unit with a swirl pot and a pressing device, wherein an air flow from the separating unit comprising the lightweight portion is flowable in the cyclone unit, wherein the air flow is directed such that the air flow circulates in the cyclone unit and thereby separates the lightweight portion from the further active material portion and conveys it downwards in the swirl pot, wherein the swirl pot is coupled with the pressing device, such that the lightweight portion is suppliable to the pressing device, wherein the pressing device is configured for compressing the lightweight portion, wherein the further active material portion, separated from the lightweight portion, is flowable out of the swirl pot together with the air flow, wherein the pressing device is in particular an edge mill, a roller press, or a briquette press.

13. System according to claim 1, further comprising a grain size separating unit which is coupled with the separating unit for receiving the heavyweight portion, wherein the grain size separating unit is configured for separating a metal portion and an active material portion, wherein the metal portion in particular comprises steel, aluminum, copper and/or compounds of the same, wherein the active material portion in particular comprises nickel oxide, cobalt oxide, metal oxide, metal phosphates, graphite and/or compounds of the same.

14. System according to claim 13, further comprising a metal separating unit which is coupled with the grain size separating unit for receiving the metal portion, wherein the metal separating unit is configured for separating the metal portion.

15. System according to claim 1, further comprising at least one of the following features: a suction unit which is coupled with the decomposing device, such that a suction flow is generatable which sucks a further part of the lightweight portion out of the decomposing unit; wherein the decomposing device comprises an integrated separating system, in particular an air classifier system, which is configured such that the further part of the lightweight portion is separatable from the heavyweight portion and the lightweight portion which are discharged at the outlet; a cyclone separator which is coupled with the suction unit, such that the suction flow is flowable in the cyclone separator, wherein the cyclone separator is configured for separating an active material from the further lightweight portion of the suction flow, wherein the active material in particular consists of nickel oxide, cobalt oxide, or their compounds.

16. System according to claim 15, wherein the cyclone separator is further coupled with the fiber compactor unit, such that the further active material from the fiber compactor unit is suppliable to the cyclone separator.

17. System according to claim 1, further comprising a housing, in which at least the decomposing device, the separating unit and the fiber compactor unit are arranged and are sealed from the environment.

18. System according to claim 17, wherein the housing comprises at least one suction opening, to which the suction unit is couplable, wherein, by the suction unit, air is dischargeable out of the housing to the environment as exhaust air, wherein in particular an air filter is arranged at the suction unit.

19. System according to claim 1, further comprising at least one conveyor, in particular a screw conveyor, a trough chain conveyor, a conveyor belt, a tube chain conveyor, a rope conveyor, a vibration conveyor, a bucket conveyor, an elevating conveyor, a Z-conveyor, a waved edge conveyor, or a scraper chain conveyor, wherein the conveyor is arranged between the outlet of the decomposing unit and the separating unit for transporting the lightweight portion and the heavyweight portion in the separating unit.

20. Method of processing battery waste, the method comprising mechanically decomposing the battery waste by a decomposing device to a, in particular strip-shaped or flake-shaped, lightweight portion and a heavyweight portion, wherein the decomposing device comprises an outlet for commonly discharging the lightweight portion and the heavyweight portion, separating the lightweight portion from the heavyweight portion by a separating unit, wherein the separating unit is coupled with the decomposing device for receiving the lightweight portion and the heavyweight portion, and compacting the lightweight portion under a separation of a further active material by a fiber compactor unit, wherein the fiber compactor unit is coupled with the separating unit for receiving the lightweight portion.

Description

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0056] In the following, for the further explanation and for a better understanding of embodiments of the present invention, embodiments are described in more detail under reference to the accompanied drawings. It is shown:

[0057] FIG. 1 shows a schematic illustration of a system according to embodiments of the invention according to an exemplary embodiment.

[0058] FIG. 2 shows a schematic illustration of the fiber compactor unit according to an exemplary embodiment.

[0059] FIG. 3 shows an exemplary illustration of a battery as battery waste.

[0060] Same or similar components in different figures are provided with the same reference numbers. The illustrations in the figures are schematic.

[0061] FIG. 1 shows a system 100 according to an exemplary embodiment. Embodiments of the present invention relate to a system 100 for processing battery waste. The system 100 comprises a decomposing device 101 for mechanically decomposing the battery waste 150, e.g. electrode foils and plastic separators, in particular to strip-shaped or flake-shaped lightweight portions 151 and heavyweight portions 152, wherein the decomposing device 101 possesses an outlet 102 for commonly discharging the lightweight portion 151 and the heavyweight portion 152. The system 100 comprises a separating unit 103 for separating the lightweight portion 151 from the heavyweight portion 152, wherein the separating unit 103 is coupled with the decomposing device 101 for receiving the lightweight portion 151 and the heavyweight portion 152. The system 100 comprises a fiber compactor unit 104, wherein the fiber compactor unit 104 is coupled with the separating unit 103 for receiving the lightweight portion 151, wherein the fiber compactor unit 104 is configured for compacting the lightweight portion 151 under a separation of a further active material 153.

[0062] The target of the processing or the recycling of battery waste 150 is the separation and a corresponding reusability of the heavyweight portions 152, active materials 153, 156 and the lightweight portion 151, 160. For this purpose, at first a decomposition, i.e. a disintegration, of the battery waste 150 in the decomposing device 101 is intended. According to embodiments of the invention, the decomposition of the lightweight portion 151 from the heavyweight portions 152 is achieved mechanically by a decomposing device 101. In the decomposing device 101, by comminuting, shredding, pressing, and cutting, the battery waste 150 is decomposed to the lightweight portion 151 and the heavyweight portion 152. Thereby, in particular the lightweight portion 151 forms thread-shaped structures which may cause a clogging. The heavyweight portion 152 which in particular consists of balled metal constituents, such that besides the thread-shaped lightweight portion 151, also sphere-shaped metal particles are present. Furthermore, in the decomposition, a further lightweight portion 160 and active material 156, which adheres to the lightweight portion 160 or is present in a free manner, are generated. These lightweight portions 160 and active materials 156 may be sucked out of the decomposing device 101 by a suction flow 154.

[0063] The battery waste 150 is delivered in capped, closed boxes and is supplied to the system 100 by a forklift, e.g. at a feeding device 107. For this purpose, the boxes are placed in a stationary lifting and tilting device by the operator, which performs the charging of the feeding funnel. The feeding funnel is above a dosing unit which ensures continuously charging the subsequent processing with a mass flow which is as homogenous as possible. The material subsequently arrives via an ascending conveyor 106 in the decomposing device 101, e.g. an impact reactor.

[0064] The decomposing device 101 comprises an upper inlet 105 for filling-in the battery waste 150. In particular, the battery waste 150 is conveyable to the inlet 105 by the ascending conveyor 106. Therefore, the battery waste 150 falls in the decomposing device 101 from above based on gravity. Therefore, during the free fall in the decomposing device 101, the battery waste 150 already slightly releases from each other.

[0065] The decomposing device 101 (e.g. an impact reactor) decomposes the battery waste 150 and balls (German: verkugelt) the heavyweight portions 152. The decomposing device 101 is operated in a batch operation with a cycle duration of approximately 10 or less minutes.

[0066] The decomposing device 101 comprises a shredder rotor. The shredder rotor comminutes and destructs the incoming battery waste 150, such that a decomposition to the lightweight portion 151, a further suckable lightweight portion 160, and the heavyweight portion 152 is enabled.

[0067] The outlet 102 of the decomposing device 101 is closable, such that, in particular by a controllable flap, the outlet can be selectively (i.e. in a controlled manner) opened for discharging the decomposed battery waste 150 out of the decomposing device.

[0068] According to a further exemplary embodiment, the flap 108 is configured for sequentially opening and for discharging the lightweight portion 151 and the heavyweight portion 152 through the outlet 102 for a predetermined discharging time. The decomposing device 101 is operated in a batch operation, so that, for example during a certain duration, the battery waste 150 is decomposed, i.e. for example shredded, destructed, etc., before the flap 108 opens the outlet 102 and the decomposed battery waste 150 is further discharged and conveyed to the separating device 103.

[0069] The discharge out of the decomposing device 101 is performed in two different lines. On the one hand, after expiry of the adjustable cycle time and/or batch operation, a discharge of the course portions, i.e. the lightweight portion 151 and the heavyweight portion 152, through the flap 108 is performed. On the other hand, the further lightweight portions 160 (e.g. fine portions and/or active materials such as nickel-cobalt-concentrate) are sucked via pneumatic units and/or suction units 113 in a suction flow 154. The suction flow 154 may continuously suck the material.

[0070] In the separating unit 103, the decomposed mixture of the lightweight portions 151 and the heavyweight portions 152 is spatially separated and is in particular discharged separately. In the separating unit 103, different mechanical separating mechanisms may be utilized. The separating unit 103 may function according to an air classifier. The separating unit 103 correspondingly comprises a blower 109 for generating an air flow. The blower 109 is controllable, such that by the air flow, the lighter lightweight portion 151 is separatable from the heavyweight portion 152, and the lightweight portion 151 is conveyable to the fiber compactor unit 104. The separating unit 103 comprises a downpipe in which the lightweight portion 151 and the heavyweight portion 152, in a loose manner, are conveyable along a conveying direction, in particular vertically falling. The blower 109 provides the air flow substantially perpendicular to the conveying direction. The separating device 103 comprises a vertical downpipe, wherein the decomposed battery waste 150 is introduced centrally from exterior. The air flow is vertically guided from the bottom to the top through the downpipe. Therefore, the lighter lightweight portions 151 are carried upwards to the fiber compactor unit 104, while the heavier heavyweight portion 152, based on gravity, falls downwards and can be further conveyed there.

[0071] The separated lightweight portion 151 is conveyed to the fiber compactor unit 104. In the fiber compactor unit 104, the lightweight portions 151 are mechanically compacted and correspondingly collected in a loading station 121 in a loading container or in another loading package, such as a big-bag, and are prepared for the further transport. In the mechanical compaction, further active materials 153 are released, which did not yet separate in the decomposing device 101 from the lightweight portion 151 or the heavyweight portion 152. In the fiber compactor unit 104, also these further active materials 153, in particular nickel oxides and cobalt oxides, can be separately discharged.

[0072] The system 100 further comprises the suction unit 113 which is coupled with the decomposing device 101, such that a suction flow is generatable which sucks a further part of the lightweight portion 160 out of the decomposing unit 101. At the mechanical decomposing device 101, by mechanically decomposing, also further lighter lightweight portions 160 are generated. In particular, the further lightweight portion 160 comprises an active material 156, in particular nickel oxide and cobalt oxide. Since these further lightweight portions 160 can be present in the atmosphere in the decomposing device 101 in a dust-type manner, by the suction unit 101, the further lightweight portions 160 are removed and are further transported for processing.

[0073] To better separate the further part of the lightweight portion 160 from the heavyweight portion 152 and the lightweight portion 151 which are discharged at the outlet, the decomposing device 101 may comprise an integrated separating system, in particular an air classifier system. The separating system in the decomposing device comprises a deflector wheel classifier, a countercurrent classifier, or a deflection classifier, for example, wherein for example a deflector wheel with a bladed rotor is used. By a feedback-controlled adaption of the circumferential speed and the amount of air of the suction flow 154 out of the decomposing device 101, a specific adaption of the separating grain size (dt) between the particle sizes of the sucked further lightweight portion on the one hand and for example the heavyweight portion 152 and the lightweight portion 151 which are discharged through the outlet 102 on the other hand is possible. Therefore, by the deflector wheel classification, the sucked further lightweight portion 160 can be separated.

[0074] The suction unit 113 may comprise a feedback and/or an inflow 118 of the air which is purified from the active material 153, 156 and other lightweight portions 151, 160 into the decomposing device 101. Thereby, a relation of the inflow to the circulating flow in the decomposing device 101 of 10% to 90% is present, depending on the material flow to be separated and the fine portion (dust).

[0075] The system 100 further comprises a cyclone separator 112 which is coupled with the suction unit 113, such that the suction flow 154 is flowable in the cyclone separator 112. The cyclone separator 112 is configured to separate the active material 156 from the suction flow 154, which in particular consists of nickel oxide, cobalt oxide, or their compounds. The cyclone separator 112 functions in a manner, that via the centripetal force, the active material 156 can be separated from the exhaust flow and can be separately processed. The exhaust air 114 of the cyclone separator 112 is blown to the outside, e.g. via air/dust filters. The discharge from the cyclone separator 112 is performed via a cell wheel lock (German: Zellradschleuse), for example. The residual material arrives in the dust filter and, by an automatic pressurized-air-cleaning, e.g. in a collecting screw. Via further conveying screws, it is transported to a double loading station 122.

[0076] The cyclone separator 112 is further coupled with the fiber compactor unit 104, such that the further active material 153 from the fiber compactor unit 104 is suppliable to the cyclone separator 112. Therefore, also the active material 153 which is obtained in the fiber compactor unit 104 can additionally be separated from the air flow and can be further processed.

[0077] The system 100 further comprises a grain size separating unit 110 which is coupled with the separating unit 103 for receiving the heavyweight portion 152. The grain size separating unit 110 is adapted for separating the metal portion 155 and an active material portion 156 which in particular comprises nickel oxide and cobalt oxide by the grain size. The metal portion 155 in particular comprises steel, aluminum, copper, and/or compounds of the same. Above the grain size separating unit, if necessary, the residual ribbon-shaped or flake-shaped lightweight portion (fibers) 152 can be deposited and sucked. This lightweight portion 151 may then also be supplied to the fiber compactor unit 104.

[0078] The system 100 further comprises a metal separating unit 111, which is coupled with the grain size separating unit 110 for receiving the metal portion 155, wherein the metal separating unit 111 is configured for separating the metal portion 155 corresponding to the electric conductivity and/or magnetic property. With the metal separating unit 111, in particular conductive and non-conductive, and/or magnetic and non-magnetic fractions of the metal portion 155 are divided. For example, a steel (Fe)-fraction 157, an aluminum-copper fraction 158, and a pure aluminum fraction 159 may be separated and isolated by their electrical conductivity and/or magnetic property.

[0079] The system 100 further comprises a housing 116 in which at least the decomposing device 101, the separating unit 103, and the fiber compactor unit 104 are arranged and are sealed from the environment. Due to the enclosing housing 116, the fine matters 154 may be kept within the housing 116 and may be specifically filtered. Via corresponding material locks, for example the battery waste 150 can be introduced in the decomposing device 101, for example via the above-described ascending conveyor 106. Furthermore, further material locks may be provided at the loading station 121, 122, 123, 124, 125, so that a material discharge of the separated residual materials out of the housing can be exchanged without undesirably discharging environmentally harmful fine particles.

[0080] The housing 116 comprises at least one suction opening 119, at which the suction unit 113 is couplable, wherein air is dischargeable out of the housing as exhaust air to the environment by the suction unit 113. At the suction unit 113, in particular an air filter is arranged. In particular, and inner housing 117 may further be provided, which in particular encloses the decomposing device 101, since especially many fine particles are generated there. The entire line from the decomposing device 101 (impact reactor) to the loading in the respective loading stations 121, 122, 123, 124, 125 is sealed and is operated at underpressure by suction at multiple positions.

[0081] FIG. 2 shows a schematic illustration of the fiber compactor unit 104 according to an exemplary embodiment. The fiber compactor unit 14 comprises a perforated plate 201, on which the lightweight portion 151, in particular the stripe-shaped or flake-shaped plastic portions of the lightweight portion 151, are disposable. The air flow from the separating unit 103 guides the lightweight portion 151 and the active material 153 in the fiber compactor unit 104. The air flow is configured such that the air flow passes the perforated plate 201 and pushes the lightweight portion 151 against the perforated plate 201 and blows the further active material portion 153 through the perforated plate 201. The fiber compactor unit 104 comprises a stripping unit 202 for stripping-off the lightweight portion 151 from the perforated plate 201.

[0082] The lightweight portion 151, in particular due to its fiber-type characteristic, remains caught at the perforated plate 201. A further active material portion 153, such as the above-mentioned metals, such as nickel oxide or cobalt oxide, remain in the air flow and pass the perforated plate 201. The further active material portion 153 may be later separated from the air flow by the cyclone separator 112 and by a filter.

[0083] By the pressure of the air flow on the lightweight portion 151 which adheres to the perforated plate 201, a compaction is achieved. This is additionally increased, since either continuously or sequentially a stripping and/or scratching of the adhering lightweight portion at the perforated plate 201 is performed by the stripping unit 202, and this released and compacted lightweight portion 151 can be collected at a loading station 121 which is coupled to the fiber compactor unit 104.

[0084] The air flow from the separating unit 103 which is carrying the material, in particular enters the fiber compactor unit 104 at the top through the tangential inlet socket, flows in particular through the cone-shaped perforated plate 201 and leaves the fiber compactor unit 104 through the outlet socket. The stripping unit 202 is configured as plugging screw (German: Stopfschnecke) and continuously strips off the deposit of the perforated plate cone 202 and densifies it due to its rotation. The pre-densified material of the lightweight portion is pushed against a membrane 203 at the lower outlet opening. By this continuous process, the material is further densified and the membrane 203 is opened.

[0085] In the loading station 121, the lightweight portion 151 is discharged, e.g. in a big-bag.

[0086] FIG. 3 shows an exemplary illustration of battery waste 150. The battery waste 150 is a used battery, for example, and firstly comprises a housing 304. The housing 304 of a battery comprises steel or aluminum, for example. In the housing 304, the electrode foils 301, 303 are located, which can function as anode 301 or cathode 303. For example, the electrode foil 301, 303 comprises two layers of metal oxides (for example nickel, cobalt), metal phosphates, or graphite, which are attached on both sides of a central layer, for example made of aluminum and copper. The electrode foils 301, 303 which function as cathode 303 on the one hand and as anode 301 on the other hand, are separated by a plastic separator 302. In the installed battery cell, the plastic separator 302 in particular has the task to electrically separate the cathode 303 and the anode 301 from each other and to ensure the ion exchange. The plastic portion of the plastic separator 302 thus forms an ion-permeable membrane. The plastic separator 302 may be formed ribbon-shaped and comprises a lightweight portion 151, 160 (e.g. polymers, e.g. polyethylene (PE) and polypropylene (PP)).

[0087] Supplementary, it is to be noted that “encompassing” does not exclude other elements or steps, and “a” or “an” does not exclude a plurality. Furthermore, it is noted that features or steps which are described with reference to one of the above embodiments may also be used in combination with other features or steps of other above-described embodiments. Reference signs in the claims are not to be construed as limitation.

TABLE-US-00001 List of reference signs:, 100 system 101 decomposing device 102 outlet decomposing device 103 separating unit 104 fiber compactor unit 105 inlet 106 ascending conveyor 107 feeding device 108 flap 109 blower 110 grain size separating unit 111 metal separating unit 112 cyclone separator 113 sucking unit 114 exhaust air 116 housing 117 inner housing 118 inflow decomposing device 119 suction opening 121 loading station plastic 122 loading station active material 123 loading station steel 124 loading station copper/aluminum 125 loading station copper/aluminum 150 battery waste 151 lightweight portion 152 heavyweight portion 153 further active material 154 suction flow 155 metal portion 156 active material 157 iron portion 158 aluminum/copper portion 159 aluminum 160 further lightweight portion 201 perforated plate 202 stripping unit 203 membrane 301 electrode foil, anode 302 plastic separator 303 electrode foil, cathode 304 housing